Thermal processing and consolidation system and method

ABSTRACT

A thermal processing and consolidation system is provided that includes an upper chamber assembly lower chamber assembly, layup and demolding station, transfer assembly, automatic or permanent coupling system, and controller. The upper and lower chamber assemblies are coupled to form an enclosed plenum operable to maintain a pressurized environment about a tool. The layup and demolding station receives the tool and facilitates the layup, bagging and sealing of unprocessed components at the tool. A transfer assembly accurately positions the tool on the lower chamber assembly in alignment with the upper chamber assembly. An automatic or permanent coupling system provides services to the tool and the enclosed plenum. A controller directs services to be supplied to the enclosed plenum and tool in accordance with a set of process parameters. This set of process parameters allows an individual set of unprocessed components to be thermally processed and consolidated.

RELATED APPLICATIONS

The present U.S. Utility patent application claims priority pursuant to35 U.S.C. §119(e) to the following U.S. Provisional Patent Applicationwhich is hereby incorporated herein by reference in its entirety andmade part of the present U.S. Utility patent application for allpurposes:

1. U.S. Provisional Patent Application Ser. No. 61/410,753, entitled“METHOD OF MAKING COMPOSITE PARTS BY USING MEMBRANE PRESS,” (AttorneyDocket No. 1189-010PRO), filed Nov. 5, 2010, pending.

2. U.S. Provisional Patent Application Ser. No. 61/495,661, entitled“RAPID CURE SYSTEM FOR THE MANUFACTURE OF COMPOSITE PARTS,” (AttorneyDocket No. 1189-011PRO), filed Jun. 10, 2011, pending.

3. U.S. Provisional Patent Application Ser. No. 61/418,521, entitled“Systems and Methods for Forming Composite components.”

TECHNICAL FIELD

The disclosure is related to a system to produce parts, such ascomposite parts, e.g., for the automobile, aerospace, sports and otherindustries utilizing composites. The system is capable of thermallyprocessing and consolidating variable size, contoured, and flat partswhile under pressure and optionally vacuum.

BACKGROUND

Composite materials are used to fabricate fiber reinforced composite(FRC) components that have found uses as critical components withinmodern, high performance aircraft, and are becoming more common interrestrial applications such as the automotive industry or sportsindustry. Composite materials are desirable for many of their inherentattributes including light weight, high strength, and stiffness.Particularly for aircraft application, those composite materialcomponents, which may be large and complex in shape, are often flightcritical necessitating strict assurance of material and structuralintegrity. Unfortunately, these materials are sometimes difficult andcostly to fabricate.

Typical composite material components comprise two or more layers ofwoven and/or unidirectional fiber filaments (e.g. carbon fibers, glassfibers, etc.) which are impregnated by a plastic resin (e.g. an epoxyresin), in a final thermally processed and consolidated state. Methodsfor forming such composite components include vacuum bag molding,pressure bag molding, autoclave molding, and resin transfer molding(RTM).

New automotive industry regulations, including the Corporate AverageFuel Economy (CAFE), Head Impact Characteristic (HIC), and PedestrianProtection, represent a challenge to conventional materials used inautomobiles, such as steel. Relative to steel, FRC components provide anexcellent combination of physical properties including strength, weight,and energy absorption. As such, FRC components are able to meet thesenew requirements, such as requirements for mass reduction and energyabsorption. However, to become cost effective replacement for steel, theamount of time and cost required to manufacture with FRC components mustbe reduced. In addition, manufacturing FRC components with aestheticallypleasing surfaces, such as Class A surfaces can be both time consumingand difficult. A class A surface is nothing more than a surfaces havingcurvature and tangency alignment to achieve an ideal aestheticalreflection quality. Class A composite surfaces can have additional classA requirements pertaining to short range waviness, long range waviness,voids, and other defects and surface features. People often interpretclass A surfaces to have curvature continuity from one surface toanother.

Composite parts are often fabricated in an autoclave that may utilizevacuum, heating, cooling, and pressure. Typical process chambers includeautoclaves, ovens, and compression presses with matched metal molds.Parts can be laid up by hand or by automated means into the mold profileand optionally bagged for vacuum forming. The prepared mold is typicallytransferred from assembly area into the process chamber by cart,conveyors, or other manual or automatic means. After closing the processchamber, the laminate is heated, formed to the profile of the mold byvacuum and/or pressure, and thermally processed and consolidated. Whenthe process is finished, the assembly is extracted from the mold.Existing systems and processes for producing high performance compositesare considered low production capacity with long cycle times, typicallyin the one hour to eight hour range. The heating is accomplished by hotair or heated molds that are slow to heat and slow to cool.

SUMMARY

Embodiments are directed to apparatus and methods of operation that arefurther described in the following Brief Description of the Drawings,the Detailed Description, and the Claims. Other features will becomeapparent from the following detailed description made with reference tothe accompanying drawings.

An embodiment for the present disclosure provides a method for thermallyprocessing and consolidating unprocessed components with a thermalprocessing and consolidation system. This method involves positioning afirst tool on a lower chamber assembly, the first tool positioned inalignment with an upper chamber assembly, the first tool in contact withand supporting a set of unprocessed components. The upper chamberassembly couples to the lower chamber assembly to form an enclosedplenum, the plenum operable to maintain a pressurized environment aboutthe first tool. Services are provided to the first tool via an automaticcoupling system where the services allow the unprocessed componentswithin the tool to be thermally processed and consolidated according toa set of process parameters.

Another embodiment provides a thermal processing and consolidationsystem. This thermal processing and consolidation system includes anupper chamber assembly, a lower chamber assembly, a first layup anddemolding station, a transfer assembly, an automatic coupling system,and a controller. The upper chamber assembly couples to the lowerchamber assembly to form an enclosed plenum, the enclosed plenumoperable to maintain a pressurized environment about a tool. The firstlayup and demolding station receives the tool and facilitates the layup,bagging and sealing of unprocessed components at the tool. A transferassembly accurately positions the tool on the lower chamber assembly inalignment with the upper chamber assembly. This transfer physicallymoves the tool from the layup and demolding station to the lower chamberassembly in alignment with the upper chamber assembly. An automaticcoupling system provides services to the tool and the enclosed plenum. Acontroller coupled to the upper chamber assembly lower chamber assemblylayup and demolding station, transfer assembly and automatic couplingsystem directs services to be supplied to the enclosed plenum and toolin accordance with a set of process parameters. This set of processparameters allows an individual set of unprocessed components to be incontact with and supported by the tool to be thermally processed andconsolidated.

BRIEF DESCRIPTION OF THE DRAWINGS

For an understanding of embodiments of the disclosure, reference is nowmade to the following description taken in conjunction with theaccompanying drawings in which like reference numerals indicate likefeatures and wherein:

FIG. 1 is a side view of a thermal processing and consolidation systemin accordance with an embodiment;

FIG. 2 is a cross section view of an automatic coupling system inaccordance with an embodiment;

FIG. 3 is a partial cross-section view of a mold tool having preformedmaterials disposed on the mold tool in accordance with an embodiment;

FIG. 4 is a partial perspective view of the mold tool with a vacuum bagdisposed on the mold tool in accordance with an embodiment;

FIG. 5 is a partial perspective view of the press and mold tool with thevacuum bag disposed over the preformed material and on the mold tool inaccordance with an embodiment;

FIG. 6 is a view of a tool-connection system plate for the automaticcoupling system that couples the mold tool with the thermal processingand consolidation system in accordance with an embodiment;

FIG. 7 is a partial perspective scaled engineering drawing of a feedmechanism to move the mold tool into the press for the press cycle tobegin and to remove one or more mold tools from the press after thepress cycle is complete in accordance with an embodiment;

FIG. 8 is a block diagram of a thermal processing and consolidationsystem in accordance with an embodiment; and

FIG. 9 is a logic flow diagram associated with a method of thermallyprocessing and consolidating unprocessed components within a thermalprocessing and consolidation system in accordance with an embodiment.

DETAILED DESCRIPTION

Some embodiments of the present invention will be now described withreference to the FIGs., like numerals being used to refer to like andcorresponding parts of the various drawings.

Embodiments provide a system for forming composite components, such ascarbon fiber reinforced plastics, glass fiber reinforced plastics, orfiber reinforced composite (FRC) components via thermal processing andconsolidation. FRC components are useful in many industries, such as inthe automotive, marine, military defense, aerospace, and medicalequipment industries. Embodiments are especially useful for formingClass A FRC body panels across entire vehicle platforms. Examples ofbody panels and related parts include, but are not limited to, hoods,fenders, roofs, rockers, splitters, roof bows, dive planes, wings,mirror caps, deflectors, etc. Further examples of FRC componentsinclude, but are not limited to, deck-lids, battery applications,control arms, bumpers, sub-frames, and other structural components.Embodiments are not limited to forming any particular type of compositearticle, and such composite components can be of various sizes, shapes,and use. It is also to be appreciated that the embodiments are notlimited to any particular industry.

An embodiment for the present disclosure provides a method for thermallyprocessing and consolidating unprocessed components with a thermalprocessing and consolidation system. This method involves positioning afirst tool on a lower chamber assembly, the first tool positioned inalignment with an upper chamber assembly, the first tool in contact withand supporting a set of unprocessed components. The upper chamberassembly couples to the lower chamber assembly to form an enclosedplenum, the plenum operable to maintain a pressurized environment aboutthe first tool. The lower assembly may be a platen (i.e. flat surface)or a surface having some volume. Services are provided to the first toolvia a service interface which may be a permanent or temporary automaticcoupling system. The services allow the unprocessed components withinthe tool to be thermally processed and consolidated according to a setof process parameters (i.e. a temperature and pressure profile).

Another embodiment provides a thermal processing and consolidationsystem. This thermal processing and consolidation system includes anupper chamber assembly, a lower chamber assembly, a first layup anddemolding station, a transfer assembly, an automatic coupling system,and a controller. The upper chamber assembly couples to the lowerchamber assembly to form an enclosed plenum, the enclosed plenumoperable to maintain a pressurized environment about a tool. The firstlayup and demolding station receives the tool and facilitates the layup,bagging and sealing of unprocessed components at the tool. A transferassembly accurately positions the tool on the lower chamber assembly inalignment with the upper chamber assembly. This transfer physicallymoves the tool from the layup and demolding station to the lower chamberassembly in alignment with the upper chamber assembly. An automaticcoupling system provides services to the tool and the enclosed plenum. Acontroller coupled to the upper chamber assembly lower chamber assemblylayup and demolding station, transfer assembly and automatic couplingsystem directs services to be supplied to the enclosed plenum and toolin accordance with a set of process parameters. This set of processparameters allows an individual set of unprocessed components to be incontact with and supported by the tool to be thermally processed andconsolidated.

FIG. 1 is a side view of a thermal processing and consolidation systemin accordance with an embodiment. This thermal processing andconsolidation system 100 includes a lower chamber assembly 102, an upperchamber assembly 104, a conveyer assembly 106 and hydraulic press 108,upper chamber assembly guide 110, a tool guide 112, a an integratedroller system 114 mounted to the tool, a push pull assembly 116, aplurality of tool placement sensors 118, air hoses 120, thermal oilhoses 122 and an automatic coupling system 124. In operations, a tool126 at a layup and demolding station 128 may be loaded with a set ofunprocessed composite material components or a set of components to bethermally processed and consolidated and/or prepped within the thermalprocessing and consolidation system provided. After the components havebeen laid up within or on tool 126, the components can be bagged.Alternatively, a membrane type press may be used to seal when a bagsystem is not used within the thermal processing and consolidationsystem. Another embodiment can use a permanently attached bag and sealsystem integrated into the upper chamber assembly. The push pullassembly 116 coupled to the tool and via the conveyer assembly 106,repositions tool 126 from the layup and demolding stations to a point onto a location on lower chamber assembly 102 in alignment with upperchamber assembly 104. A hydraulic press 108 may be used to couple andmaintain pressure between the upper chamber assembly 104 and lowerchamber assembly 102. The lower chamber assembly and the upper chamberassembly join together to create the plenum. Various sensors 118 alongthe tool guide 112 reports the position of the tool 126 to a controller(not shown) that directs the operation of the thermal processing andconsolidation system.

Once aligned, the upper chamber assembly is lowered by the hydraulicpress 108 to form a pressure seal with lower chamber assembly 102. Thetool 126 aligns and mates to automatic coupling system 124. Automaticcoupling system 124 may provide a variety of services to the tool and anenclosed plenum formed by the upper chamber assembly 104 and lowerchamber assembly 102. These services may include high pressure fluids orgases used to pressurize the environment of the plenum about tool 126.Vacuum can be used to withdraw air or other gases from the set ofcomponents to be thermally processed and consolidated at tool 126.Thermal oils in one embodiment may be used to heat via conduction and/orconvection the components to be thermally processed and consolidated.Other embodiments may position radiators, infrared panels, resistiveheating panels or other heating systems to provide heat to thermalprocessing and consolidation of the components within tool 126. As thetool may encompass 80% or more of the plenum, (with or without the useof spacers and partitions) the heat exchange systems provide a moreefficient method of controlling the thermal profile of the componentsduring processing than previously available when using a traditionalautoclave. For example, in an autoclave the tools may take less than 20%of the chamber volume. This means that rapid changes in temperature inan autoclave are either very inefficient thermally, that the tool andmaterial is heated unevenly due to the low thermal transfer rates ofmost autoclaves and the high thermal mass of most tooling, and as aresult even heating and control of the autoclave, tooling and materialis difficult to achieve. Runaway exothermic reactions in certainmaterials, due to limited thermal transfer capability of mostautoclaves, is another drawback of most autoclave systems which can heatthe autoclave air at relatively fast rates, but which do not havesufficient thermal energy transfer rates to draw sufficient exothermicheat out of the material. The thermal processing and consolidationsystem described herein has thermal transfer capabilities sufficient forcontrolling most exothermic reactions, which are typically a result offast heating rates of reactive materials. The components at tool 126 arethermally processed and consolidated according to a pressure andtemperature profile maintained as a set of process parameters andexecuted by the controller. After thermally processing andconsolidating, the plenum is depressurized prior to opening. Also priorto opening, the automatic coupling system may be retracted from thetool. This automatic coupling system is a self-sealing system such thatthermal oils, hydraulics or other fluids contained within the tools, donot leak within the plenum on the lower chamber assembly from either thetool side or the upper chamber assembly side of the automatic chambercoupling system. The upper chamber assembly is raised to a height toaccommodate the insertion and withdrawal of tool 126.

FIG. 2 is a more detailed cross section of the automatic coupling system124 in accordance with an embodiment. FIG. 2 shows upper chamberassembly 104 with automatic coupling system 124 penetrating the upperchamber assembly 104. This coupling system will include an externalconnections 202 for the various services and internal self-sealingconnections 206 that provide self-sealing and automatic coupling betweentool 126 and the automatic coupling system 124. As previously described,the services provided to external connections 202 may include thermalfluids to heat and/or cool the tool and components according to the setof process parameters, vacuum to withdraw gases from the unprocessedcomponents, gasses or fluids to pressurize the plenum according to theset of process parameters, a communication pathways to exchangeinformation and/or control signals between the tool or plenum and thethermal processing and consolidation system, injection materials to beinjected into the unprocessed components, and/or hydraulics to actuatemechanical systems within the automatic coupling system that allow thetool to be secured to the automatic coupling system. Withdrawing gassesserves not only to remove gasses, but also reduces voids that wouldresult if the gasses were not removed. Withdrawing gasses through vacuumapplication consolidates the laminate by creating a differentialpressure, causing the membrane/vacuum bag to compress the laminate atatmospheric pressure, or the differential pressure, if partial vacuum isutilized. The differential pressure created by the vacuum applicationunderneath the membrane/vacuum bag allows positive atmospheric pressure(greater than one atmosphere and up to 500 psi or more) to be exertedonto the materials placed between the tool and the membrane/vacuum bag.

Hydraulics can be used to operate locking mechanisms that secures thetool to the automatic coupling system 124. The coupling system lockingsystem can be hydraulic or electro-mechanical. Hydraulic push/pullsystem 208 allows for engaging/disengaging the tool with the chamberassembly. In other embodiments, push/pull system 208 may also serve asan engaging/disengaging mechanism that provides the locking mechanism.Communication pathways may provide an electronic or optical path forsensor information collected within the plenum or from the tool to beprovided from the automatic coupling system to the controller. This mayallow for the controller to monitor and control various stages of theprocess executed during the process, manipulate the flow of thermaloils, or the heat transfer between the tool and exterior sources.Further, identification encoded on the tool may be provided via acommunication pathway to the controller to ensure that the proper set ofprocess parameters is selected based on the components and the tool id.Although optional, identification encoded in the tool facilitates aseamless connection between the tools and associated stored processparameters, so that when using multiple unique tools in one system, thestored process parameters are automatically selected based on the toolin position to be processed.

In at least some embodiments, suitable preform tools are used tosupport, layup, bag and seal the unprocessed components. These tools mayuse fluids to heat and cool the tool, with the preform tool used to formthe composite components.

FIG. 3 is a view of a mold tool having preformed materials disposed onthe mold tool in accordance with an embodiment. Mold tool 300 caninterface with press 302. Press 302 may also be referred to as apressure press, or bladder press, or diaphragm/membrane press. The moldtool 300 is useful for holding unprocessed components 304 thereon.Optionally, unprocessed components 304 are formed with the preform tool,and generally include a fiber mat and resin. This may include carbonfiber, glass fiber, preimpregnated fiber and plastic fiber mats; andresin film layers or injected resins. Components could also be manuallyor automatically formed directly in the tool. The mold tool 300 can beheated and/or cooled to interact with the resin of the unprocessedcomponents 304.

FIG. 4 is a partial perspective view of the mold tool. FIG. 5 is partialperspective view of the mold tool with the vacuum bag disposed over thepreformed material and on the mold tool. Referring to FIGS. 4 and 5,vacuum bag 306 is shown disposed on the mold tool 300. The vacuum bag306 is useful for forming the FRC component from the unprocessedcomponents 304. The vacuum bag 306 can be of various configurations. Thevacuum bag 306 is re-sealable with an integrated release for ease ofuse. The bag may include a stack of materials including seal tape, peelply/release film (sometimes perforated), breather layer, and barrierfilm topped by a flexible membrane (silicone is common), or single usevacuum bag film. In one embodiment, the bagging system is a one-piecereusable bag that includes a preformed silicone membrane with apermanent release film coating on the material side of the bag, and anintegrated breather/seal perimeter. The vacuum bag 306 can be evacuatedand is useful for driving the resin into the fiber mat of theunprocessed components 304. In other embodiments, the resin may beinjected into the unprocessed components layed up in the tool as one ofthe supplied services provided through automatic coupling system. Incertain embodiments, the vacuum bag 306 provides for the elimination ofcomponents, such as a breather layer, release film, and/or tape. Otherembodiments may incorporate vacuum bag in an interior surface of theupper chamber assembly or use a membrane incorporated with the upperchamber assembly for formng the FRC components.

FIG. 6 is a view of a tool-connection system plate for the automaticcoupling system that couples the mold tool with the thermal processingand consolidation system. The tool-connection system 600 includesexterior and interior connections 602 for feed and return of thermalfluid, exterior and interior connections 604 for a vacuum line, a staticline 606 for pressure monitoring of the mold tool, exterior and interiorconnections 608 for pressurizing the enclosed plenum and a communicationpathway connection 610 for the exchange of information such as but notlimited to a resistive thermal device (RTD) for temperature monitoringand providing feedback of the mold tool. Temperature monitoring may alsobe implemented by thermocouples, optical pyrometers and other likesystems. Embodiments may monitor the actual temperature or the rate ofchange in the temperature. The tool-connection system includes aplurality of connections for connecting various elements to the moldtool 300, such as fluid feeds, fluid returns, and sensors. In general,the elements provide services and communication with the mold tool 300.These elements are generally in communication with the mold tool 300,such as being in fluid communication with the mold tool 300.

In some embodiments the tool-connection system includes a resistivethermal device (RTD) male and female connector for temperaturemonitoring and feedback of the mold tool 300. In addition to oralternate to an RTD, other forms of temperature and pressure measurementof the mold tool 300 can also be utilized. These forms includethermocouples, optical pyrometers and other like systems. Embodimentsmay monitor the actual temperature or the rate of change in thetemperature.

The internal connections of the self-coupling system include connectionsfor feed and return of thermal fluid, connections for a vacuum andstatic line for pressure monitoring of the press, and a communicationpathway connection (optical or electrical) to relay for temperature andpressure monitoring data and identification data to the controller. Theinternal connections 600 of the automatic coupling system also include athermal fluid exhaust valve 602 for feeding thermal fluid to the tool, athermal fluid intake valve 604 for returning the thermal fluid, a firstalignment pin 612, a vacuum connector 605 and a static connector 606 forpressure monitoring of the plenum, a locking ring operated by hydraulicactuators supplied by connector 607, and a second alignment pin orbushing 614.

By pressurizing the plenum, pressure is applied to the mold tool 300 andunprocessed components during a press cycle to form the FRC componentfrom the unprocessed components 304. The plenum and mold tool 300 have apressure, temperature and or vacuum profile which is imparted by theinternal connections 600 of the automatic coupling system. The thermalprocessing and consolidation system includes a lower frame forsupporting the mold tool 300.

Operation of the thermal processing and consolidation system, includingpositioning of the tool and the temperature and pressure applied ismonitored and controlled by a programmable logic controller (PLC). ThePLC may be implemented using shared processing devices and/or individualprocessing devices. Processing devices may include microprocessors,micro-controllers, digital signal processors, microcomputers, centralprocessing units, field programmable gate arrays, programmable logicdevices, state machines, logic circuitry, analog circuitry, digitalcircuitry, and/or any device that manipulates signals (analog and/ordigital) based on operational instructions. The memory may be a singlememory device or a plurality of memory devices. Such a memory device maybe a read-only memory, random access memory, volatile memory,non-volatile memory, static memory, dynamic memory, flash memory, and/orany device that stores digital information. Note that when the basebandprocessing module implements one or more of its functions via a statemachine, analog circuitry, digital circuitry, and/or logic circuitry,the memory storing the corresponding operational instructions isembedded with the circuitry comprising the state machine, analogcircuitry, digital circuitry, and/or logic circuitry.

Typically, connection between the mold tool 300 and the thermalprocessing and consolidation system is automated with a commonconnection design after the upper chamber assembly joins the lowerchamber assembly. Specifically, the tool and the internal connections600 of the automatic coupling system couple and engage with one anotheronce the mold tool enters the plenum. Once coupled, the mold tool 300and the thermal processing and consolidation system are in fluid (and,typically, electrical communication) with one another. Coupling of theelements is generally as follows (once the mold tool 300 and automaticcoupling system are brought together): the vacuum connectors couple, thestatic connectors couple, the male locking pin and the female lockingring couple, the alignment bushings and the alignment pins couple, theRTD male connector and the RTD female connector couple, the thermalfluid intake valves couple, and the thermal fluid exhaust valves couple.The fluid containing connections are self-sealing to prevent the leakageof fluids to the plenum during this procedure. Such a configurationprovides for manufacturing versatility, such as allowing for multipletool variations (e.g. mold tool 300 variations) to be utilized with noaffiliated change over time. For example, various configurations of moldtools 300 can be utilized and simply “plugged into” the thermalprocessing and consolidation system via the connection system. It is tobe appreciated that the mold tool 300 can be of various sizes, shapes,and configurations.

The thermal processing and consolidation system can create a closedpressurized environment capable of being pressurized to variouspressures in various amounts of time depending on the needs of theunprocessed components. For example, the thermal processing andconsolidation system can create an enclosed plenum capable of beingpressurized to about 150 psi in about 2 minutes. The plenum can also bepressurized to higher or lower than 150 psi, in various amounts of timegreater or less than 2 minutes. The processing pressure being in therange of 80 to 150 psi, but could be more or less depending on materialand desired part characteristics. The processing pressure in at leastsome embodiments can be significantly greater than 150 psi; for exampleone embodiment may use a pressure of about 300 psi. Similarly, theprocessing pressure in at least some embodiments can be significantlyless than 80 psi. The pressure or pressure range selected depends uponthe properties of the unprocessed components and resins, materials, oradhesives used in processing.

In at least some embodiments hydraulic actuator system within the upperchamber assembly of FIG. 1 provides selective pressure to some or theentire mold tool 300, and therefore presses the unprocessed components304. A human machine interface (HMI) such as a graphical user interface(GUI) can be used to monitor and control process parameters associatedwith the process. The process parameters include pressure, vacuum,and/or temperature of the plenum and tool during the process cycle

FIG. 7 is a partial perspective scaled engineering drawing of a feedmechanism to move the mold tool into the press for the press cycle tobegin and to remove one or more mold tools from the press after thepress cycle is complete in accordance with an embodiment. Feed mechanism700 feeds the mold tool 300 into the thermal processing andconsolidation system for the press cycle and removes the mold tool 300from the thermal processing and consolidation system after the presscycle. The feed mechanism 700 can couple to a tray to hold, send andreceive the mold tool 300. In at least one embodiment, the feedmechanism is a powered pusher/puller bar that couple to the tool ortray. In at least some embodiments, the tray may interface with theupper chamber assembly and lower chamber assembly to form the pressureboundary. The tray may also have internal lines and connections thatallow the services to be provided to the tool through the shuttle tableor tray. The tray may also be part of the lower chamber assembly.

FIG. 8 provides a block diagram of a thermal processing andconsolidation system 800 in accordance with an embodiment. Thermalprocessing and consolidation system 800 includes a process chamber 802,at least one layup and demolding station 804, optional additional lay-upand demolding station(s) 806, transfer assembly 808, coupling system810, controller 812, and service modules 814. Process chamber 802provides a pressurized enclosed plenum that may be formed from an upperchamber assembly joining a lower chamber assembly wherein the upperchamber assembly is coupled and uncoupled to the lower chamber assemblyvia a hydraulic press system 816. The layup and the molding station 804receives a tool 818 wherein the tool may serve as a support forunprocessed components to be processed, i.e., thermally processed andconsolidated within the process chamber. Layup may involve layup,bagging and sealing the unprocessed components to the tool 818 prior totransfer from the layup and demolding station 804 to the process chamber802 via the transfer assembly 808.

Controller 812 couples to a sensor network 820, hydraulic press 816,process chamber 802, layup and demolding stations 804, optional layupand demolding stations 806, transfer assembly 808, coupling modules 810,and service modules 814. The transfer assembly directs movement of thetool from the layup and demolding station 804, to process chamber 802.The tool is positioned such that the tool can couple to coupling modules810 in an automatic fashion. The controller 812 may then direct theprocess chamber to be closed and the services such as heating, cooling,pressurization, vacuum, and the exchange of information/data can beprovided via the service module(s).

The controller 812 directs the service modules to execute a set ofprocess parameters that cures the components laid-up within tool 818according to a predetermined pressure, temperature, and/or vacuumprofile.

In at least some embodiments, additional layup and demolding stationsare provided that may receive additional tools 822. This allows anadditional set of unprocessed components to be laid-up, bagged andsealed in tool 822 while a first set of unprocessed components areprocessed on tool 818. This allows throughput to be greatly enhanced byallowing the process chamber downtime to be minimized to only the timerequired to transfer a tool in and out of the process chamber.

Coupling system 810 may penetrate the process chamber walls, lowerchamber assembly or a tray supporting tools and provide services to theinterior of the process chamber and the tool as required by the set ofprocess parameters. All these coupling systems may be self-sealingsystems such that process fluids are not leaked within the processchamber or on the tool. These services again may include thermal fluidsto exchange heat with the tool or other heat exchange structures locatedwithin the process chamber, vacuum to withdraw gases from theunprocessed components, gases to pressurize the enclosed plenum of theprocess chamber 802, communication pathways that allow sensors withinthe process chamber and tool to communicate process data back tocontroller 812. Further identification information associated with thetool 818 or tool 822 may be used by controller 812 to determine the setof process parameters to be executed in order to cure the unprocessedcomponent. Injection materials such as resins may be injected intounprocessed components laid-up and bagged within the tool while the toolis already located within the process chamber. Hydraulics may also beused to secure the tool to the coupling system as directed by controller812. To expedite processing, tools 818 and 822 may comprise a cradlethat receives a slipper. This slipper can hold a set of unprocessedcomponents. When the slipper is received at a layup and demoldingstation, the slipper may be placed as a unit on a cradle to facilitatethe layup of the components within the tool. Numerous slipper tools canbe used where the labor associated with the layup in the slipper tool issubstantially longer than the thermal processing/consolidation cycle.The slipper tool approach allows for reduced cost when compared tocreating numerous complete tools. The slipper may comprise the outershell, which can be “laid-up” and vacuum bagged, prior to being placedinto the heated cradle tool which transfers in and out of thechamber/plenum.

These components may be made from composite materials, utilizingreinforcing fibers such as but not limited to glass, carbon, ceramic,metallic or polymeric fibers; composite matrix materials such as but notlimited to thermosetting polymers, thermosetting polymeric matrixcomposites, thermoplastic polymeric matrix composites, thermoplasticpolymeric resins, thermosetting polymeric resins; fiber/metalinterleaved laminates, fiber/low-density-core interleaved composites,low-density-cored composite laminates, metal matrix composites, lowmelting point metals, low melting point metal matrix composites; andmetals with adhesives or polymeric adhesives.

The plenum of process chamber 802 may have a variable volume affected bythe installation and removal of spacers or partitions in order to allowthe volume of the plenum to substantially match the size of the toolbeing processed. Other types of heating and cooling may include the useof infrared radiation and/or microwave radiation.

FIG. 9 is a logic flow diagram (e.g., performed by controller 812)associated with a method of thermally processing and consolidatingunprocessed components within a thermal processing and consolidationsystem in accordance with an embodiment. Operations 900 begin in block902 wherein a first tool is positioned on a lower chamber assembly. Thefirst tool is positioned in alignment with an upper chamber assemblywhere this first tool supports a first set of unprocessed components.These components may be metal, composite materials, fiberglass,thermoset materials, thermoplastics or other like materials. In block904 the upper chamber assembly and lower chamber assembly join or coupleto form a plenum. This plenum may provide a pressurized environmentabout the tool and unprocessed components to be in contact with andsupported therein. The pressurized environment may be controlled to havea specific pressure profile to support the processing of the unprocessedcomponents within the upper chamber assembly. In block 906 services areprovided to the tool in the plenum via a coupling system. The servicesmay include the provision of injection materials, gases or fluids topressurize the plenum, thermal oils or fluids used to exchange heat withthe tool or heat exchange structures within the plenum, communicationpathways to exchange information, data and/or electrical signalsincluding power signals to the tool and other features within theplenum, and vacuum where vacuum may be applied to the unprocessedcomponents in accordance with the set of process parameters.

In block 908 the unprocessed components are processed or thermallyprocessed and consolidated within the plenum as directed by a set ofprocess parameters. Further steps associated with the processing ofunprocessed components may be the engagement and disengagement of thetool as a plenum via a coupling system. As previously described theservices may be permanently attached to the tool and/or plenum or ascurrently described they may be coupled or uncoupled as needed. Theupper chamber assembly may be opened in such a manner to minimize theseparation between the upper chamber assembly and the lower chamberassembly such that the opening is sufficient only for the transfer oftools to and from the alignment positions within the plenum. Thispositioning may be facilitated by a transfer assembly that couples to alayup and demolding station where the tool may be prepared forprocessing and the process component may be removed after processing.This transfer assembly may in at least some embodiments simultaneouslywithdraw one tool from the plenum while positioning an additional toolon the lower chamber assembly in alignment with the upper chamberassembly for further processing. This minimizes the time that the plenumneed be opened.

In summary, embodiments provide a thermal processing and consolidationsystem. This thermal processing and consolidation system includes anupper chamber assembly, a lower chamber assembly, a first layup anddemolding station, a transfer assembly, an automatic coupling system,and a controller. The upper chamber assembly couples to the lowerchamber assembly to form an enclosed plenum, the enclosed plenumoperable to maintain a pressurized environment about a tool. The firstlayup and demolding station receives the tool and facilitates the layup,bagging and sealing of unprocessed components at the tool. A transferassembly accurately positions the tool on the lower chamber assembly inalignment with the upper chamber assembly. This transfer physicallymoves the tool from the layup and demolding station to the lower chamberassembly in alignment with the upper chamber assembly. An automaticcoupling system provides services to the tool and the enclosed plenum. Acontroller coupled to the upper chamber assembly lower chamber assemblylayup and demolding station, transfer assembly and automatic couplingsystem directs services to be supplied to the enclosed plenum and tool.

As one of average skill in the art will appreciate, the term“substantially” or “approximately”, as may be used herein, provides anindustry-accepted tolerance to its corresponding term. Such anindustry-accepted tolerance ranges from less than one percent to twentypercent and corresponds to, but is not limited to, component values,integrated circuit process variations, temperature variations, rise andfall times, and/or thermal noise. As one of average skill in the artwill further appreciate, the term “operably coupled”, as may be usedherein, includes direct coupling and indirect coupling via anothercomponent, element, circuit, or module where, for indirect coupling, theintervening component, element, circuit, or module does not modify theinformation of a signal but may adjust its current level, voltage level,and/or power level. As one of average skill in the art will alsoappreciate, inferred coupling (i.e., where one element is coupled toanother element by inference) includes direct and indirect couplingbetween two elements in the same manner as “operably coupled”.

The foregoing description of some embodiments of the invention has beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed, and modifications and variations are possible in light of theabove teachings or may be acquired from practice of the invention. Thespecifically described embodiments explain the principles and practicalapplications to enable one ordinarily skilled in the art to utilizevarious embodiments and with various modifications as are suited to theparticular use contemplated. It is intended that the scope of theinvention be defined by the claims appended hereto, and theirequivalents. Further, it should be understood that various changes,substitutions and alterations can be made hereto without departing fromthe spirit and scope of the invention as described by the appendedclaims.

1. A method for thermally processing and consolidating unprocessedcomponents within a thermal processing and consolidation system,comprising: positioning a first tool on a lower chamber assembly, thefirst tool positioned in alignment with an upper chamber assembly,wherein the first tool contacts and supports a first set of unprocessedcomponents; coupling the upper chamber assembly and the lower chamberassembly to form a plenum, the plenum operable to maintain a pressurizedenvironment about the first tool; providing services to the first tooland the plenum via a service interface; and thermally processing andconsolidating the first set of unprocessed components within the firsttool wherein the services are supplied to the first tool as directed bya set of process parameters.
 2. The method of claim 1, wherein the firsttool substantially fills the plenum.
 3. The method of claim 1, whereinthe first tool fills about 80% of the plenum.
 4. The method of claim 1,further comprising: disengaging services from the first tool and theplenum via the service interface, the service interface comprising anautomatic coupling system; uncoupling the upper chamber assembly fromthe lower chamber assembly to form a separation between the upperchamber assembly and the lower chamber assembly; and withdrawing thefirst tool via the separation, a height of the separation substantiallymatching but greater than a height of the first tool.
 5. The method ofclaim 4, further comprising: positioning at least one additional tool onthe lower chamber assembly, the at least one additional tool positionedin alignment with the upper chamber assembly, while simultaneouslywithdrawing the first tool from the plenum, the at least one additionaltool contacts and supports at least one additional set of unprocessedcomponents.
 6. The method of claim 1, wherein the services comprise atleast one of: thermal fluids to heat and/or cool the componentsaccording to the set of process parameters; vacuum to withdraw gasesfrom the first set of unprocessed components in the first tool; gassesto pressurize the plenum according to the set of process parameters;communication pathways to exchange information and/or control signalsbetween the first tool and the thermal processing and consolidationsystem; injection materials to be injected into the unprocessedcomponents; or locking actuators to lock the mechanical systems of thefirst tool to the coupling system.
 7. The method of claim 6, wherein theinformation comprises a tool identifier, the set of process parametersselected based on the tool identifier.
 8. The method of claim 6, whereinthe information comprises process data, the process data used by the setof process parameters.
 9. The method of claim 1, further comprising:collecting process data by at least one sensor embedded in the firsttool, material, and/or plenum.
 10. The method of claim 9, wherein theprocess data comprises temperature, pressure and/or material state data.11. The method of claim 1, wherein the automatic coupling system is aself-sealing system.
 12. The method of claim 1, further comprising:laying up, bagging and sealing the first set of unprocessed componentsin the first tool at a first layup and demolding station of the thermalprocessing and consolidation system.
 13. The method of claim 1, furthercomprising: laying up, bagging and sealing the first set of unprocessedcomponents in the first tool at a first layup and demolding station ofthe thermal processing and consolidation system; and laying up, baggingand sealing at least one additional set of unprocessed components in atleast one additional tool at an at least one additional layup anddemolding station of the thermal processing and consolidation system;the laying up, bagging and sealing of the at least one additional set ofunprocessed components occurs while the first tool is within the plenum.14. The method of claim 1, wherein the set of process parameterscomprises a temperature, pressure and/or vacuum profile to be applied tothe unprocessed components.
 15. The method of claim 1, wherein theunprocessed components comprise at least one type of unprocessedcomponents selected from the group consisting of: composite materials,comprising: glass, carbon, ceramic, metallic and/or polymeric fibers;and composite matrix materials comprising thermosetting polymers,thermoplastic polymers; thermosetting polymeric matrix composites,thermoplastic polymeric matrix composites; thermoplastic polymericresins, and or thermosetting polymeric resins; fiber/metal interleavedlaminates; fiber/low-density-core interleaved composites;low-density-cored composite laminates; metal matrix composites; lowmelting point metals; low melting point metal matrix composites; andmetals bonded with polymeric adhesives.
 16. The method of claim 1,further comprising: reducing a volume of the plenum to substantiallymatch a size of the first tool.
 17. The method of claim 1, wherein aheating/cooling profile of the set of process parameters is supplied byat least one heat transfer method selected from the group consisting of:conduction and/or convection from circulating fluids; conduction and/orconvection from electric heaters; conduction and/or convection fromradiators; infrared heating; and microwave heating.
 18. A thermalprocessing and consolidation system, comprising: an upper chamberassembly; a lower chamber assembly, the upper chamber assembly operableto couple to the lower chamber assembly and form an enclosed plenum, theplenum operable to maintain a pressurized and/or temperature controlledenvironment; a first layup and demolding station to receive a firsttool; a transfer assembly operable to position the first tool on thelower chamber assembly in alignment with the upper chamber assembly fromthe first layup and demolding station; an automatic coupling system orpermanent connection to provide services to the first tool and theplenum; and a controller coupled to the upper or lower chamber assembly,the transfer assembly and the automatic coupling system, the controlleroperable to direct the services to the first tool in accordance with aset of process parameters, the set of process parameters operable tocure a first set of unprocessed components within the first tool. 19.The thermal processing and consolidation system of claim 18, furthercomprising at least one additional layup and demolding station toreceive at least one additional tool, the controller operable to directthe withdraw of the first tool to the first layup and demolding stationwhile simultaneously positioning the at least one additional tool fromthe at least one additional layup and demolding station to the lowerchamber assembly in alignment with the upper chamber assembly, the firsttool to be withdrawn following thermal processing of unprocessedcomponents within the first tool.
 20. The thermal processing andconsolidation system of claim 18, wherein the automatic coupling systemor permanent connection penetrates the upper or lower chamber assemblyto supply services to the first tool within the enclosed plenum.
 21. Thethermal processing and consolidation system of claim 18, wherein theautomatic coupling system comprises a tray, the tray operable to: coupleto the first tool, the upper chamber assembly and the lower chamberassembly; deliver services to the tool and the plenum; and form theplenum in combination with the upper chamber assembly and the lowerchamber assembly.
 22. The thermal processing and consolidation system ofclaim 21, wherein the tray is operable to couple to at least oneadditional tool, the tray operable to: reposition such that the at leastone additional tool is aligned to the upper chamber assembly and thelower chamber assembly; and form the plenum in combination with theupper chamber assembly and the lower chamber assembly about the at leastone additional tool.
 23. The thermal processing and consolidation systemof claim 18, wherein the automatic coupling system or permanentconnection penetrates the upper or lower chamber assembly to supplyservices to the first tool within the enclosed plenum.
 24. The thermalprocessing and consolidation system of claim 18, wherein the automaticcoupling system and tool are self-sealing systems.
 25. The thermalprocessing and consolidation system of claim 18, wherein the servicescomprise at least one of: thermal fluids to heat and/or cool theunprocessed components according to the set of process parameters;vacuum to withdraw gases from the unprocessed components in the toolwithin the enclosed plenum; gasses to pressurize the enclosed plenumaccording to the set of process parameters; communication pathways toexchange information and/or control signals between the tool within theenclosed plenum and the thermal processing and consolidation system;injection materials to be injected into the unprocessed components; ormechanical systems actuated by hydraulic, electric, or pneumatic meanswithin the tool within the enclosed plenum.
 26. The thermal processingand consolidation system of claim 18, wherein: the first layup anddemolding station facilitates layup, bagging and sealing a first set ofunprocessed components in the first tool.
 27. The thermal processing andconsolidation system of claim 18, wherein the first tool comprises acradle to receive a slipper comprising the first set of unprocessedcomponents, the slipper received at the first layup and demoldingstation.
 28. The thermal processing and consolidation system of claim18, wherein the set of process parameters comprises a temperature,pressure and/or vacuum profile to cure the unprocessed components. 29.The thermal processing and consolidation system of claim 18, wherein theunprocessed components comprise at least one type of unprocessedcomponents selected from the group consisting of: composite materials,comprising: glass, carbon, ceramic, metallic and/or polymeric fibers;and composite matrix materials comprising thermosetting polymers,thermoplastic polymers; thermosetting polymeric matrix composites,thermoplastic polymeric matrix composites; thermoplastic polymericresins, and or thermosetting polymeric resins; fiber/metal interleavedlaminates; fiber/low-density-core interleaved composites;low-density-cored composite laminates; metal matrix composites; lowmelting point metals; low melting point metal matrix composites; andmetals bonded with polymeric adhesives.
 30. A thermally processed andconsolidated material made by a process, comprising: a set ofunprocessed components, wherein the unprocessed components comprise atleast one type of unprocessed components selected from the groupconsisting of: composite materials, comprising: glass, carbon, ceramic,metallic and/or polymeric fibers; and composite matrix materialscomprising thermosetting polymers, thermoplastic polymers; thermosettingpolymeric matrix composites, thermoplastic polymeric matrix composites;thermoplastic polymeric resins, and or thermosetting polymeric resins;fiber/metal interleaved laminates; fiber/low-density-core interleavedcomposites; low-density-cored composite laminates; metal matrixcomposites; low melting point metals; low melting point metal matrixcomposites; and metals bonded with polymeric adhesives. the componentslayed up, bagged and sealed within a first tool; the first toolpositioned within a plenum of a thermal processing and consolidationsystem, the thermal processing and consolidation system operable toprocess a single tool, a volume of the plenum substantially matching avolume of the first tool, the first tool and the plenum coupled toservices by an automatic coupling system operable to provide services tothe first tool and the plenum from the thermal processing andconsolidation system, heat exchanged between the thermal processing andconsolidation system and the set of unprocessed components, the heatexchanged in accordance with a set of process parameters executed by thethermal processing and consolidation system, the heat exchanged tothermally process and consolidate the set of unprocessed components toproduce the thermally processed and consolidated material; and thethermally processed and consolidated material demolded from the firsttool.